Gamefisher Gamefisher 298.586180 User manual

MODEL NO.
298.586180
, owner's
responsibility
. maintenance
. operation
, trouble
shooting
. replacement
parts

TABLE OF CONTENTS eageNo.
'SPECIFICATIONS .......................................... !
OWNER'S RESPONSIBILITY ................................. 2
MAINTENANCE .......................................... 4
LUBRICATION GEAR HOUSING ........................... 4
MUFFLER INSPECTION .................................. 4
PROLONGED STORAGE ................................. 4
OPERATIONS ........................................... 4
NEW AUTOMATIC CLUTCH ................................. 4
BOAT MOUNTING ...................................... 5
STEERING ADJUSTMENT ................................ 5
2-CYCLE ENGINE FUEL MIXTURE ......................... 6
STARTING PROCEDURES ....................... ......... 6
STOPPING PROCEDURES ................................ 6
FLOODING ........................................... 7
CARBURETOR ADJUSTMENTS ............................ 7
PROPELLER SHEAR PIN ................................. ?
EGNITION SYSTEM ..................................... 8
REMOVING MOTOR FROM BOAT .......................... S
SALT WATER OPERATIONS .............................. 8
TROUBLE SHOOTING CHECK LIST .......................... 9
REPLACEMENT PARTS .................................... 10
ORDERING PROCEDURES ...................... Outside Back Cover
PRODUCT WARRANTY ............. :.......... Outside Back Cover
SPECIFICATION
Type of Engine ........................... Air Cooled 2-Cycle
Horsepower ....................................... 1.76
Maximum RPM .................................... 8000
Weight .................. (9 kg) ......... 19.8 Lbs. Approx.
Bore and Stroke ........... (36 mmx 30 mm) .... 1.42" x 1.18"
Displacement ............. (30.5 cc) ............. 1.86 cu.in.
Fuel Capacity-Engine Tank .... (0.8 liters) .... .......... 4/5 qt.
Ignition ....... Flywheel Magneto with Transisterized Electronic Ignitor,
Spark Plug .................... NGK BMR-6A or Champion RCJ-8
Spark Plug Gap Setting ....... (0.6 ram) ................. 025"
Bearings(Engine) .................................... Ball
Bearings(Gear Hsg.) ....................... Ball & Oilite Bronze
Starter ......................................... Recoil
Propeller Dia. and Pitch ...... (171 mmx 104.4 mm) 6.73" x 4;11"
Lub. {Gear Hsg.) ............. _..................... SAE 90
Fuel Mixture ... 50 to 1ratio of regular grade gasolineto 2-cycle outboard
lubricant or its equivalent BIA certified TC-W 2-cycle outboard lubricant.
Steering ................................ 243 ° Pivot Steering

IMPORTANT -
Owner's Responsibifity and Operating Safety Check List
BE SURE TO READ AND DO THE FOLLOWING BEFORE
OPERATING YOUR OUTBOARD MOTOR
SAFETY CHECK LIST
I. Learn and obsenle the boating laws of the U.S. Coast Guard, state, local author-
ities.
2. U.S. Coast Guard regulations require the following:
a. Provide an approved life-vest, type 1, 2 or 3, Personal Flotation Device for each
person in boat. (Encourage passengers to wear them.)
b. If the boat exceeds 16 feet, also carry atype 4, throwable Personal Flotation
Device.
3. Do not fill fuel tank wtth motor running or near any flame or lighted smoktng
material,
4. When loading boat distribute lhe load evenly, keep the load low; don't overload;
don't stand in asmall boat. Take weather and water conditions into account.
5, Do not permit persons to ride on parts of the boat not designed for such use.
Standing, bow riding and seat back or gunwale riding can be especially dangerous.
OWNER'S RESPONSIBILITY
6. Read owner's manual before running your new outboard motor.
7. Before starting, make sure your motor is securely mounted to boat transom with a
safety chain. Tighten clamp stud handles securely by hand.
8. Be sure to have pliers, screwdriver, spare spark plugs, wrench, shear pins and cotter
pins in boat whenever leaving shore.
g. Be sure to have an adequate supply of fuel (carry only in an approved container) on
board. Use a good grade of regular gasoline with proper mexture, as cited in the
Specifications.
10. Occasionally check to be sure clamp stud handles on transom mounting bracket are
t=ght.
t 1_ IN CASE OF AN EMERGENCY, THE ENGINE CAN BE STOPPED BY DEPRES-
SING THE STOP BUTTON {IF SO EQUIPPED) OR PLACING CHOKE KNOB IN
FULL CHOKE POSITION.
|2. Keep an alert lookout. Serious accidents have resulted from failure to use eyes.
13. Keep firefighting and lifesaving equipment in good condition and readily accessible
at all times.
14. GOod housekeeping is ever_ more important attoat than ashore. Cleanliness dimin-
ishes the probability of fire and tripping hazards.
TIPS FOR TRAILERING OR AUXILIARY USE
15_ When launching or loading boat on a trailer, place vour outboard motor in the
tilted storage position. Also when trailering your boat and outboard motor, keep
outboard motor in upright (vertical) position on the boat transom. Outboard
motors transported across rough roads in the "tilt" position could cause transom
damage or mounting brackets to break off, losing your motor. If motor must be
trailered in "'tilt" position, a short length of 2 x4 should be placed between the
motor bracket and the motor leg. The motor leg should then be firmly tied down
against the 2 x 4 to prevent any puss=hie damage. Similar precautions should be
taken if using the motor as an auxiliary power source for asadboat or power boat.
When using motor as an auxiliary power source, the use of an auxiliary adjustable
position motor bJ'acket is recommended.
2

MAJOR PARTS
ChokeLever
PowerHead
SparkPlug
DualAutomaticClulchHousing--
ReverseDrivingLock
Fuel SedimenlBowl
and Filler
Till PinAdiustmenl
MufflerPipe
ExhaustOullel
Propeller
CoHerPin
GearHousingCover
fji----'_ StarlerHandle
StepButton
Fuel$hul-ofiValve
TwistGdp
SleedngHandle
ClampSludHandles
TransomBracket
DriveShallPil_e
CavllalionPlate
Fill and DrainPlug
GearHousing
Figure I
MAINTENANCE
1. FEATURE INFORMATION
e. This outboard motor has special design
features as shown in Figure I.
b. Your selection of our Marine Products will
provide you with many hours of enjoyable
boating. To assure your complete satisfac-
tion on the investment you have just made,
we ask you to read this manual thoroughly
before going afloat. Acquaint yourself with
the particular areas of operation on your
outboard motor as you read the step-by-step
procedures. Keep in mind maximum pep
formence is achieved only when the owner
or Operator is completely familiar with the
operating instructions.
c. Periodic servicing will be required. It is
recommended that you con_lt your Sears
Service Center when service is necessary.
We will be happy to extend our facilities
and assure prompt service.
//
Fiaure 2
Figure 3
FiLL AND
DRAIN PLUG
_SING
k_ COVER
-COTTER PIN
3

MAINTENANCE
2. LUBRICATION -- GEAR HOUSING
a. The Gear Housing has been pre-lubricated at
the factory; however, the grease level should
be checked as follows using SAE 90 out-
board motor grease. (See Figure 2).
(f) Prior to initial operation.
(2) After first four (4) hours of use.
f3) Recheck after every fifty (50) hours
running tame.
(4) Replace with new lubricant at the end
of your outboard motor season. This
is =mportant, as it removes any water
from the gear housing and prevents
possible corrosion tO intern!l parts.
b. To Check, Drain or Fill gear housing, follow
these steps:
{1) Position outboard motor upright.
{2) Remove drain plug and washer, then
insert nozzle of gear lubricant tube
into hole.
(:3) Squeeze tube until lubricant is forced
out around tube.
(4) Replace plug end washer. Be sure plug
is tightened securely.
(5) To achieve complete drainage of lubri-
cant, remove cotter pro, propeller and
shear pin from propeller shaft, also,
gear housing cover by unscrewing 2
bolts.
(6) When lubrMcant has comptetelydrained.
replace parts and refill gear housing
using filling procedure above.
c. For best results, lubricate propeller shaft
with lithium grease every 30 to 60 days.
3. MUFFLER INSPECTION
a. Periodically remove muffler cover by un-
screwing screws and inspect for carbon
build-up inside the muffler inlet and outlet,
the exhaust port and the combustion
chamber of the cylinder, Excessive carbon
will prevent drawing the maximum power
out of the engine. (See Figure 3).
b. Care should be exercised while cleaning
away carbon to prevent scratches to the
surface of the engine components and drop-
ping carbon inside of crankcase.
4. PROLONGED STORAGE
a. To store your outboard motor for pro-
longed storage, prepare outboard as fol-
lows:
(1) See paragraph on stopping procedures.
tRef. 10)
(21 When removing outboard motor from
boat, allow all water to drain from
unit.
b.
c.
(3) The outboard motor should b_
mounted on astand vertically with
power head up for storage.
(4) Pull starter handle _lowty until resist-
ance is felt due to compression pres-
sure. then stop. Release starter tension
SlOWly tO prevent engine from revers-
ing rotation due to compression
pressure. This positlon will close both
the intake and exhaust ports for
storage.
(5) Drain and fill gear housing as outlined
under Lubrication of Gear Housing.
(Ref. 2)
{6) Wipe exterior completely with fresh
water cloth and then apply light coat-
ing of oil.
When starting a new season, always use fresh
gasoline. Last year's gasoline may have
varnish deposits that will plug the carbu*
retor jets, thus requiring a complete over-
haul.
To plan for the coming season, we recom-
mend you contact your Sears Service
Center before the new season for any service
repair work required.
OPERATION
5. NEW AUTOMATIC CLUTCH
a. New automatic clutch. Based on adual
centrifugal clutch design, it allows the outJ
board prop to turn at very slow speeds or
even come to a complete stop while the
engine continues operating efficiently. It
eliminates the need to shift gears by hand
and prevents the engine from overheating
and stalling at slow speeds.
When engine starts, motor is neutral. As
throttle increases, sub clutch engages= At
appx. 6 MPH, main clutch engages to
provide direct drive for crmsing.
4

OPERATION
6, BOAT MOUNTING
a. Mount the motor on the center of the boat
transom (stern). {See Figure 4).
CAUTION
Hand tighten transom bracket and clamp
stud handles slmultaneousty. Do not use a
wrench or any other device that would
caur,ed=Tnage to brackets. Occasionally
check to be sure lamp stud handles on
transom mounting bracket are tight.
{See Figure 5),
b. To obtain the best performance from your
outboard, the following boat transom speci-
fications are recommended: (See Figure 4).
Transom Angle (See View 3):
........... 12 re 15degrees
Transom Height (See View 4):
.............. 20.7 inches
c. The angle of the motor column is easily
adjusted by removing the Hitch Pin and
changing the Tilt Lock Bracket Pin in the
five {5) different angle position holes
located on either side of the r=ght or left
Transom Mounting BraCkets. Each angle
positron elevates five (5) degrees. Try
center hole posztion first. (See Figure 6).
d. To find the correct angl .__position, make a
test run at full throttle- with your usual
loading in the boat. Always stop motor to
change the Titt Lock Bracket Pin. Thecor-
rect angle position will have your boat
traveling with the bow slightty higher than
the stern, but should not porpoise (bow
rises and falls rapidly and continuously). Be
sure Tilt Lock BraCket Pm is always pushed
completely through both Transom Mount-
_ng Brackets and Hitch Pin is secured.
WARNING
If the motor column is tilted too far out-
ward, the boat is likely to porpoise or
cav_tate at full throttle, which con be
dangerous because a cross wind or awave
could suddenly deflect the boat into a
dangerous turn. Also, if the motor
column is tilted too far inward, the bow
of the boat will dig in, which can be
dangerous when' crossing awake or in
rough water. Do not run motor in the
storage positiOn_ f,?_ee View 1 and 2.
Figure 4).
e. Secure motor to boat with Safety Chain.
Chain not included with motor.
,_12 Dto "Vmw t
_20=7"
Figure 4 wew4
TRANSOM
Figure 5
Figure 6
7, STEERING ADJUSTMENT
Tighten steering tension bolt using a spanner
for desired steering effort.(See Figure 6).
CAUTION j
There is a possibility of losing bolt if
backed out too far.

OPERATION
8. 2-CYCLE ENGINE FUEL MIXTURE
Use a good grade of regular gasoline. (See mix-
ing table below.)
CAUTION
Always use BIA certified TC-W oil in the
50:1 ratio. Failure to do so may result in
exee_ive spark p}ug fouling, pi==ton
SCoring, or bearing failure. Do not under
shy circumstances, use multigrade, such as
10W-300 or other automobile oils,
If BIA certified oil is not available, ul_
an SAE 30 or 40 2-cycle or outboard oil.
We reserve the right to refuse warranty on
parts which are damaged when using
improper fuels or lubricants.
WARNING
Gasoline Is highly flammable. Always mix
in well ventilated area, Do not fill tank
with motor running, nor near any flame
or while smoking. Be sure vent screws
end filler caps on tanks are finger tighte-
ned when transporting gasoline in the
trunk of your automobile to prevent
explosion.
FUEL
MIXING
TABLE
50:1
MIXTURE
U.S. Measure
Regular Amount of ell
Gasoline to be added
In Gallons In Pints In Oz
t O.16 2.6
3 0.48 7.7
5 0.80 12.8
6 0.96 15.4
Metric Measure
Regular Amount of oil
Gasoline to be added
In Liters In Liters
1 O.O2
5OotO
10 0.20
20 0,40
9. STARTING PROCEDURE (See Fig, 7 8=7A)
a. Open air vent screw located on fuel filler
cap by turning counterclockwise.
b. Open fuel shut-off valve.
c. Open throttle grip to hatf throttle.
d. Move choke lever to "On" position.
WARNING
When starting outboard, the boat will
move with asudden burst of speed. Make
sure you are well seated so as not to lose
your balance with a fast start.
FiBure ?
Figure 7A
Figure 8
e. Pull starter handle slowly until you feel
starter engage. Then pull with rapid
motion and allow the starter cord to
retract slowly. (See Figure 8).
f. After engine hat started, gr_fuelly move
choke lever to "Off" position while
warming up the engine.
g. Let engine idle for approximately 3
minutes before moving throttle grip to
"'Fast" position.
10. STOPPING PROCEDURE
To stop engine, move throttle grip to "Slow'"
position end press stop button.(See Figure 7A)
6

oPERATiON
WARNING
In case of an Emergency, the engine can
be stopped by moving the Choke Lever to
Full Choke Position.
If the motor will not be operated for a
period of time, if it is to be removed from
the boat. or if it is to be tilted up, we
recommend the foitowlng practice to
prevent _piUage from the carburetor
throat and bowl and to prevent gum
formations in the carburetor during
ztorege:
1. Close fuel shut-off valve and air
vent r,crew at fuel fiUer cap.
2. Allow motor to run at idling speed
until it stops of its own accord,
indicating the carburetor has run
dry.
11. FLOODING
To clear engine of excess fuel, move choke lever
to "Off" position and throttle grip to half
throttle POsition, Pull recoil starter handle
until engine starts and continues to run.
12. CARBURETOR ADJUSTMENTS
a. Your motor has a idle adjusting screw and
the idle speed has been preset at the factory,
However, you may need to adjust the idle
speed using Idle Adjusting Screw, Turn the
Screw clockwise tO increase motor speed
and counter c_ockwise to decrease it. The
=die speed adiustment must be done with
throttle grip at full closed position and the
idle speed should be as low as possible while
the engine runs steady. {See Figure 9)
b. Periodically check filter for dirt by unscrew-
ing Sediment Bowl.
13. PROPELLER SHEAR PiN & COTTER
PiN HOLDER
a. The Shear Pin ,s used for the purpose of
protecting the Drive Train arbd Gears. The
Shear Pin wil! not prevent the propeller
from becoming dama9ed when striking an
under water object. When shear pin is
broken, the eng=ne will continue to run,
however, the propeller will not be rotating.
tCAUTION ]
Stop engine immediately after shearing
pin to avoid possible damage to the engine.
b. To replace shear pin, shut oft motor,
remove cotter pin with ptiers and sl_p off
propeller. (See Figures 10 & 1 lj.
c, Replace.with new shear pin located in shear
pin and cotter pin holder. (See Figure 12).
Z_._tdleAdjustingScrew
Fl=mre 9
Figure 10
Figure 11
Figure ! 2

OPERATION
14. FLYWHEEL MAGNETO IGNITION
SYSTEM WITH TRANSISTERIZED
ELECTRONIC IGNITOR
a. The magneto ignlt!on system consists of the
following component parts: Flywheel, Tren-
sizterized Electronic Ignitor and Ignition Coil.
b. Inspect the following if engine fails or is
hard to start:
(I} Spark plug as often as necessary. Be
lure spark plug gap setting is ,025"'
(0.6mm).
(2) Gasoline fuel supply and fuel shut-
off valve should be open.
(3) Carburetor being starved of fuel.
c, The correct spark plug for this motor is
NGK BMR-6A or Champion RCJ-8.
d. To test ignition system, remove spark
plug and place against bare spot on metal
part of motor away from cylinder spark
plug hole and then pull starter cord several
times, if a spark bridges the plug gap, the
magneto is in good operating condition.
The high tension lead wire must be con-
nected to the plug for this check, if there
ts no spark, have the ignition checked at
your Sears Service Center.
15. REMOVING MOTOR FROM BOAT
a. Always tilt motor by lifting on rear of
shroud. DO NOT PUSH DOWN ON THE
STEERING HANDLE, When removing the
motor from the boat, raise the outboard in
upward direction until the propeller clears
the transom. Hold the motor upright long
enough to allow all water to drain from the
exhaust pipe. When you find it difficult to
hold the motor upright, tighten the Center
Bolt increasingly for desired effort, (See
Figure 13).
WARNING
Although the engine is air cooled, it is
possible to burn your hands on the engine
block and upper portion of the column.
Do not touch.
b. It may be necessary to rotate the motor to
one side before tilting the motor on the
transom to remove leg from the water when
installed on boats with thick transoms.
c. Always carry outboard with the engine
above the lower unit to prevent moisture
from entering the engine through the
exhaust ports.
d. Steering handle serves as carrying handle as
shown in Ffgure 14,
Figure 13
Fi ure 14 WARNING
If the motor will not be operated for a
period of time, if it is to be removed
from the boat, or if it is to be tilted up,
we recommend the following practice to
prevent spillage from the carburetor
throat and bowl and to prevent gum
formations in the carburetor during
storzKje:
t. Close fuel shut-off valve and air vent
screw at fuel filler cap.
2. Allow motor to run at idling speed
until it stops of its own accord, indi-
cating the carburetor has run dry.
16. SALT WATER OPERATION
To materially increase the life of all exposed
parts and decorative finishes, follow the steps
indicated below.
a. Always tilt your motor out of the water
when not in use.
b. Never leave the lower unit in salt water
overnight.
c. Wipe exterior completely with fresh water
cloth and then apply light coating of oil.
d. Lubricate propeller shaft occasionally with
a waterproof type of lubricant (Lithium
Grease), thus enabling the propeller to be
removed easily.
e. It is good practice when operating in salt
water to inspect your motor daily and to
apply alight coating of grease to any
part or area that show= evidence of cor-
rosion or rust.
f. Always remove motor from boat ver-
tically, allowing water to drain from column
before tilting the motor.
8

TROUBLESHOOTINGCHECKLIST
*Take your otttdboMd motor into euy one of over
2000 Sea. Senei_ Units.
X X Fuel Tank Empty'
X X "- Fuel Shut-Off Valve'Closed
X X X 'X Fuel Line Kinl(ed or Pinched
-- X X X Fuei' Filter Dirty or C1o9_
X X X X Vent Screw on Fuel Tank F'ilter Cap Oozed
X X X X Carburetor Passages Clogged or Dirty
X X X X X Incorrect Fuel-Oil Mixture
X X X X X Carl_retor Out of Adjustment "'
X X Engine Flooded
X X X' X X Wrong Type Spark Plug
X X X X X Defective or Fouled Spark Plug
X X Defective Magneto °
XSpark Does Not Jump Spark Plug Gap *
XEngine Out of Time , ""
X X X X Transisterized Etectronic I_itor o_t of order "
X X X X X Weak Ignition Coil ...... "
X X Spark Plug Lead Wire Not Secured
X X Frayed or Cracked Lead Wire Insulation °
X X Di_oon_ted. Grounded or Loose Wiring in ElectrJca! System- *
X Propeller Bound by Foreign Objects (Fir_hing Line. Weeds. Etc.)
X High Tension Lead-Sail Water Build Up
IMPORTANT INFORMATION
MODEL NUMBER: 298.586180
SERIAL NUMBER
DATE OF PURCHASE
INSURE YOUR ENGINE
Many insurance companies includ,ng Allstate
Insurance offer protection contracts for your
boat and outboard engine. Insurance covering
your own equipmen! aga=nst damage, theft,
etc,, as well as liability insurance for property
damage and personal injow to others is availa-
ble, It would be wise to contact your insurance
agent for further information about adequate
protection.
IDENTIFICATION PLATE
9
OPERATING LOG
DATE
J
NO. HRS. USED GAL_ FUEL USED DATE NO. HRS. U_EO GALS. FUEL USED

REPLACEMENT PARTS
FOR
MODEL No.298.586180
IO

m
80
81
6
5
a
£
Z
BI

FIG. 1 ENGINE
R .No.
1-001
|-002
1-003
I-OH4
1-005 •
I-OOE
i-007
1-008
!-009
1-010
l_O|i
1-012
1=013
1-014
1-o1$
!-o17
I-OIL
1-019
1~O2O
1-021
1-022
1-023
1-024
|-024
1-024
1-024
1-024
1-025
1-026
1-027
1-029
| -030
1-031
!-032
!-033
!-034
!-055
1-085
1-060
1-007
1-008
! -074
! -075
1-07U
1-077
1-070
1-079
1-080
1-001
P.P.No.
010-01046-200
115T-04000-000
018-00546-200
002-01046-800
017-01000-204
040-0|000-201
041-01000-201
i039-0|000-200i
OSl-O|OOO-20O
i037-01000-200
i04G-O1058-SO0
060-02000-200
070o02401-201
'099-81620-200
Egg"OOlS3-600
990-62101-G04
173-0105E-800
700-00601-203
F992-01050-011i
i788-00601-203
822-00601-200
793-10200-201
071-0200T-200
071-0200T-210
071-02007-220:
071-02007-2301
071-02007-240
990-61020-200
900-6HlS2-SO0_
iogo-OlOOO-200
072-01058-800
IET-ZOT50-EO0
lO$-llEO0-80D
155_21711-000
_!!2-0105E-300
202-01003-201!
256-01040-200
000-11050-|02
092-01050-041
960-11050-382
092-10050-042
990-11050-202
902-10050-042
005-00000-200i
086-00000-2001
090-11050-202
002-10050-042
992-10060-042
991-01060-021
PARTS NAME Q'ty
cvLIHpkiBatHED"'' 1
SPATE PLUG CAP ASS'Y !
SPATE FLOG ENSUE !
CTLIEDE| COHP. 1
CTLIHOEB GASKET 1
PISTOl RING /TOP 1
PISTON tlHO 1
PISTON rim CIRCLIP 2
PISTOH 1
PISTOl PIN lOESO 1
C|AES. SNAFT CONF. 1
VOOD-BBPF El! 311315 1
CtAH| SHAFT MASHER 16.2222 2
BALL BKAtlHG 80202 I
OIL SIAL 15257 1
NEEDLE |KAtlaQ FIOIOS 1
PBIMABV CORD CONPo 1
STAETKt PAHL.SPRIH6 2
VASARI 5 2
STAR?MR PEEL 2
STARTER PAUL SHIM O.UT 2
STEP°BOLT 2
CRATE SHAFT SWIM 0.05 V
CRAM[ GNAFT SHIM 0,10 V
CtAaX SHAFT SHIN 0.15 iV
CRANE SHAFT SHIN 0.20 iV
CLANK SHAFT SHIM 0,30 !
BALL BEARING J6202 1
OIL SEAL 15257 |
CLAW[ CASE GASKET 1
CRANE CASE ASS'Y 1/
IGNITION: COIL COMP, i
COtD CLAMP COMP, 1
EAGHETO tOTOt ASS'¥ !
FAS:CAS! !
SECONDARYCORD gtoNNE? 1
SPARK PLUG tUBBER COVEt B i1
$CEEV SX10 4
VESSEl 5 4
SC|EV 5X38 4
S.VASHES 5 4
sctKv 5X20 12
S.VASHEt 5 !I
FLYVE_SL VASHB,
FLYVH_EL HUT 12 1
SCtEE 5120 _4
S.VASHER 5_4
S.EASHEt 5_4
HUT 0 14
12

,role P
73 Im
€
,,,,I
4
65 66
49
23,24 25 28
27
56 55",
19
5857
C
"I'1
i=
I'll
IW

FIG.2 TANK, CLUTCH & MUFFLER
REF,No. P.P.No.
2-002 s,5-351oo-.o2
2-003 300-35300-200
2-001 EU0-35100-203
2-005 401-35300-200
2-011 682_01058-200
2-012 SU2_IO2OI-UO0
2-013 594-00517-200
2-014 170-01046-800
2-015 266-00503-203
2-018 181-01004-200
2-017 180-01004-200
2-018 021-36100-201
2-010 700-1450U-OB2
2-020 700-14508-057
2-021 680-01004-200
2-022 701-00517-200
2-023 398-01000-202
2-024 395-01225-200
2-025 394-01202-201
2-026 399~0|000-200
2-028 309-01000-210
2-020 309-01000-220
2-026 399-01000-230
2-027 390-01040-200
2-028 397-01202-201
2-029 410-10201-900
2-031 333-01046-200
2-032 347-01048-201
2-033 2|0-35300-800
2-034 358-10|12-200
2-035 290-10112-802
2-030 359-10112-203
2-037 357-10|12-204
2-038 342-10205-220
2-039 g92-OlOBO-O]l
2-040 091-01020-011
2-041 737-01000-20I
2-042 710-01046-200
2_043 737-01040-200
2-044 717-01046-200
2-045 221-35500-200
2-044 228-35500-200
2-047 _220-JS300-200
2-048 225-35500-200
2-049 227-35500-200
2-050 UU0-11040_252
2-051 902-10040-042
2-052 090-liOOO-IG2
2-053 992-10o00-042
2-054 090-11030-I01
2-055 090-11040-182
2-056 992-10040-042
2-05? 900-11040-302
2-058 :092-10040-042
2-059 9D0_11040-122
2-060 992-10040-042
2-OOl 990-11000-202
2-002 992-10080-042
2-003 000-11050-122
2-054 992-10050-042
2-005 !990-110B0-252
2-OUH 902-10060-042
2-067 090-11050-122
2-000 692-i00U0-042
2-000 !092-01050-041
2-070 990-11060-122
2-071 002-10060-042
2-072 012-35500-200
2-073 011-35100-200
2-075 159-21401-B71
2-076 092-10040-042
2-077 U90-11040-122
2-091 330-35306-200
2-002 331-35308-200
2-093 :UOU-3530H-200
2-0U4 336-35118-200
F_ARTS NAME
TANK CAP ASS'Y
EBOIBB COVER
TANK $UffOKT |]NH
TANK
'ET-COCK BRACKET
PUT-COCK ASS'¥
PET-COCK FIXIU6 NUT
STOP UUTTOB
STOP BUTTON COVEt
SPECIAL S.HASHEU
STOP BUTTON FIX|UO mUT
PIN HOLDER
FUEL PIPB 4.SXBXU2
FUEL PIPE 4,SXBX6?
CLIP U
FUEL PIPE STOPPER
iRKED VALUE SEAT GASKET
REED HOLDUP
fREED ,ALVE A
tEED VALVE COLLAR k
2EBU VALVE COLLAR B
IEED VALVE COLLAI C
tEED VALVE COLLAR D
IHLET NAUIFOLD
itEEO VALUE SEAT
All CLEANEU ASS'Y
CLUTCH HOLDING BASE
!CLUTCH FLANGE
CLUTCN SPBIBO CONF.
CLUTCH HASBE| A
CLUTCH AIH COHP.
ECLUTCU VASN£2 B
CLUTCH STEP BOLT
CLUTCH SPRING
HAStiER 8
BEE. NUT 8
MUFFLER GASKET
NUPPLKt BODY A
HUFFLEI UASIET
HUPFLE2 BODY O
HU_PLER PIPE GASKET
NUPFLE2 PIP_ STAY A
MDFFLED PIPE
HUPFL2R PIPE BRACKET A
MUFFLER PIPE BIACKET B
SCREU 4X25
S.EASUEU 4
SCIEU OXIG
S.EASHE2 6
SCREV 3XlO
SCIEB 4116
S.VASHE2 4
SCEEE 4230
S.VASH£2 4
SCIEV 4II2
S.VASUEB 4
SCIEV HI20
S.VASBER 6
SCK_U 5112
S.VASEU2 5
SCIEV OX2S
3.VASflEt 6
SCIEV 5112
$.UASKEN 5
VASHEI 5
SCBEU 0112
iEUASUEt e
SHEA| PIN
COTTE2 P1m
IUHITO2 COHP. TT[-IF
S.VASHEI 4
SCIEU 4X12
BlUeT SIDE MAll
LEFT SID_ MANE
RANK PLATE
STARTE2 HAte
Q'ty
1
1
1
I
I
I
!
!
1
3
1
I
1
|
2
2.
2
2
1
1
1
!
I
3
3
3
3
3
3
i
1
i
!
t
!
!
I
1
i
1
3
3
3
3
2
B
U
2
2
S
5
2
2
2
2
!
i
3
3
3
2
2
2
1
2
2
I
1
!
!
14

FIG.3 RECOIL STARTER
O--
5
17 16
REENo.
3-000
3-001
3-002
3-003
3-004
3-OOS
3-008
3-007
3-008
3-004
3-010
3-011
3+OIZ
3-013
3-014
3-015
1-016
3-017
P.P.No.
75U-OOS37-gO0
772-00537-200
774-04015-204
770-01006-20t
T76-01008-207
7A3-00517-200
780-00601-201
785-10207-201
773-0010U-204
814-00S00-200
g_0-11050-122
902-10050-042
992-0|060-041
DO2-lOOUO-O_2
491-41060-022
?H2-0054U-2D0
833-|0207-200
9g2°Ot040-Ol]
PARTS ' NAME
IEC01L STAITEI ASS'Y
IHCOIL STAITEI BOOT
STAtTE| HOPE IEEL
HECOIL SPHIRG
PULLET SHAFT
STAETE| HOPE 3.5Xt300
=OPE GUIDE
STA|TE| _ANDL£
PULLET SHAFT/OUTE|
STA|TEU POLLEY SHIN
5CIEV SIt2
S.VASHE| S
VASHE| fl
S.VASHE| 6
CAP MDT 6
|OP[ |ECEIIE
STAETER dANDLE CAP
VASHEH 4
O'ty
1
I
!!
!
!
1
1
!
2
2
!
l
l
I
I
!
15

FIG.4 CARBURETOR
o--
22
o
23
12
14
REENo.
4-000
4-001
4-002
4-003
4-004
4-005
4-006
4-007
4-008
4-000
4-010
4-011
4-012
4-013
4-014
4-015
4-015
4-017
4-025
4-019
4-020
4-021
4-022
4-023
P.P.No.
i455_2290T-001
500-22004-200
:507-22904-200
505-22900-200!
594-22602-200j
010-22000-2001
503-22900-200
592-203AA-930
501-20|B(-200
623-22900-200
622-22907-200
561-22600-900
007-22900-200
509-2002K-880
606-22900-200
094-34040-|21
605-22900-200
603-22615-800
028-22900-Z00
804-22903-200
629-22904-200
904-31040-081
570-22903-200
990-11040-061
PARTS .... NAME
CARDUUETO| ASS'Y
RUBBER CAP
CABLE ADJUSTER
BODY CAP
THROTTLE VALVE SPRING
THROTTLE SPRING RECEIV_
JET NEEDLE CLIP
3£T NEEDLE ASS'Y 011333
THROTTLE VALVE I.OXi. I
ADJUSTER SPRING
ADJOSTEZ SCREV
BODY BAND ASS'Y
CBAHBER GASKET
HAIR JET 168
FLOAT CBAXBEB
SCIEV 4112/S
FLOAT ARH PI#
NEEOLE VALV_ CO_P.
FLOAT ARH
FLOAT
DRAIN GASRET
SC|EV 4XD
GASKET
SCREV 4X6
O'ty
!
i
1
1
1
1
!
!
I
I
1
!
!
!
!
2
1
!
!
1
16

FIG.5 HANDLE & BRACKET
52 •54 45
47
41 .35
2O
36
39
28
25-
26
-30
29
33
32
31
37
4O
I'/

FIG.5 HANDLE & BRACKET
REENo. P.P.No.
5-OOO 870-35552-000
5-001 8a5-01058-800
5-005 200-36300-800
5-006 993-51042-002
5-007 999-B1600-404
5-008 903-50020-002
5-oog 185-35300-203
S-OlD 990-21080-252
S-Oil 902-I0060-042
5-012 990-11050-202
5-013 902-I0050-042
5-014 161-35500-202
5-015 793-10200-201
5-010 992-04080-D31
5-017 160-35552-500
5-019 162-35U00-200
5-020 990-21080*302
5-02I 992-01080-041
5-022 991-01080-021
5_023 992-10080-042
5-024 134-35500-201
5-025 115-35300-210
5-026 131_3530B-20(
5-027 136-35500-201
S-02E 090-21050-102
5-029 ggo-ilOSO-IE2
5-030 902-10050-042
5-031 137-35500-201
5-032 138-35500-201:
5-033 D92-10050-042+
5-034 U90-11050-122
5-035 i139-35500-200
5-036 129-35100-200
5-037 i123-35500-201
5-038 i107-35118-U01
5-039 i!06_35110-801
5-040 9B0-21050-752
5-041 I103-36501-200
5-042 991-41060-022
5-043 U92-10050-042
5-044 992-01060-041
5-045 871-36552-200
5-046 872-35552-200
5-047 B73-35552-200
5-048 U74-35552-200
5-04_ H75-35552_200
5-050 876-35552-200
5-051 879-35552-200
5-052 090-11050-202
5-053 991-01050-021
5-054 877-35552-200
5-055 D78-35552-200
5-056 003-32201-200
PARTS NAME Q'ty
TglsT 6tIP A'S5'T 1
THROTTLE MIlE COUP, 1
CLUTCM DRUM COUP, I
STOP llJO C42 1
BALL BEARING gBO04OD 1
STOP lING C20 1
iCLOTCM CASE 1
MEX. BOLT 6125 2
+S.VASgEI 5 2
+SCIEV 5120 4
iS,BASM£I 5 4
!HAMDLB STOPPER l
+STEP BOLT I
VAVK UASUEI 8 1
5TUEE|iG MAMOLE COUP. :1
HANDLE VASUEI +2
BOLT BX30 I
VASMEM 8 I
HOT 8 I
S.VASBER 8 I
THRUST gASHED I
BRACIZT I
TMtOST BRACIBT 4
IETUMM CAM 1
BOLT 5IIO 1
SCIEV 5XlH 1
S.MASHEI 5!
METUIM CAM GUIDE I
RETURN GUIDE PLATE |
S.MASMEI 5 4
SCIEV Oil2 4
RETUMM SPRING 1
MIACKET PIN STOPPEU Al
UIACRET Plm S 1
CLAMP BSACKET B COUP. 1
CLAMP BUACIET ACOUP. I
BOLT 6X75 l
CLAMP BRACKET 8USHIBG 2
CAP MUT 0 1
S.VASBER 6 I
BASHER OI
THROTTLE gRIP 1
THROTTLE INNER PIPE 1
THROTTLE BOLDER A1
THROTTLE BOLDER M
:TKNOTTLE MOLDER COVER
VlBg GUIDE I
TAPPING SCUEV 2
SCIEV 5X20 2
MOT 5 2
THROTTLE STOPP_E i!
THROTTLE 5TOPPEM SPRIUG PI
Mile CLAMP BAND +1
118

FIG.6 DRIVE SHAFT PIPE & GEAR CASE
26
27
28 i .
25
29
23
30
36
20
22
71
15
19
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